A review on plastic moulding manufacturing process and parameters

They study the effect of melting temperature, injection time, packing pressure, packing time and cooling time on the warpage with the help of Teguchi andANOVA.Gruber et al., 2014Study vi

Peer-Reviewed Journal ISSN: 2349-6495(P) | 2456-1908(O) Vol-8, Issue-8; Aug, 2021

Journal Home Page Available: https://ijaers.com/

Article DOI: https://dx.doi.org/10.22161/ijaers.88.3

A Review on Plastic Moulding Manufacturing Process and Parameters

Shailesh Singh1, Sunil Sahai2, Manoj Kumar Verma3

1M.Tech Student, Department of Mechanical Engineering, Institute of Engineering & Technolgy Dr Ram Manohar Lohia Avadh

University, Ayodhya, India

2,3Assistant Professor, Department of Mechanical Engineering, Institute of Engineering &Technolgy Dr Ram Manohar Lohia Avadh University, Ayodhya, India

Received:22 Aug 2020;

Received in revised form: 19 Oct 2020;

Accepted: 30 May 2021;

Available online: 09 Aug 2021

©2021 The Author(s) Published by AI

Publication This is an open access article

under the CC BY license

(https://creativecommons.org/licenses/by/4.0/)

Keywords — Injection moulding, Parameters,

Machining, Quality, Maintenance

Abstract— Injection Mold Design is the process of designing and

developing the tools, methods and techniques needed to improve efficiency and productivity The basic management conditions are learned from conceptual development to product production The impact of varied factors studied supported processing parameters Since quality and productivity are two important conflicting goals in any machining process Quality has got to be somewhat compromised, ensuring high productivity Similarly, productivity is reduced, but efforts to enhance quality are channelized to make sure top quality and productivity, it's necessary to optimize the machining parameters Various reactions of injection molding process quality supported performance parameters and methods are studied the purpose of this paper is to illustrate the state of the plastic injection molding process The working conditions are satisfied by the production of a product based on high quality.

Modern-day injection molding tools are often a complex

arrangement of mechanical, electrical, pneumatic, and

hydraulic components that are expected to fulfill many

demanding tasks Whatever the complexity, mold design

must specify a device that will work satisfactorily in

production Injection molding is the most commonly used

manufacturing process for making plastic parts A wide

variety of products can be made using injection molding,

which can vary greatly in their size, complexity, and

application The injection molding machine, raw plastic

material, and mold are required for the injection molding

process The plastic is dissolved in the injection molding

machine and then injected into the mold, where it cools

and freezes at the end.This is one of the process that are

greatly preferred in manufacturing industry because it can

produce complex-shape plastic products and having good

dimensional accuracy with short cycle times typical

examples are automobile industry, casings and housings of

products such as computer monitor, mobile phone and which has a thin shell feature

Much research is being done to understand the important factors and design the molding processes Much of the work over the past decade has been based on: theoretical, computer-based simulation models and practical experimental tests (Erzurumlu & Ozcelik, 2006)used the Taguchi method to reduce the variance and sink index In his study he considered mold temperature, melt temperature, packing pressure, rib cross section and rib layout angle and material PC / ABS, POM, PA66 They found in their research that PC / ABS plastic products, rib cross-sectional pom material plastic production and rib layout angle effect PA66 materials significantly affect plastic production (Ozcelik et al., 2010)attempted to study the mechanical properties of materials using the Taguchi method They are considered the melting temperature,

packing time, cooling time, injection pressure (L Zhao et

al., 2010)study the sink marks error with simulation with

the help of software mold flow and experiment with the

Taguchi method In their research they study the process

parameters on polypropylene content and solubility, mold

temperature Injection Time, Pressure Holding, Cooling

Time.(Stanek et al., 2011)A mold design study with the

help of cadmol software They claim that Cadmold

software can calculate curing time based on molding time,

speed and vulcanization time, and material and technical

parameters (Saman et al., 2009)Study the mold condition

of the injection mold to create the proper molding system

through CAD / CAE devices They represent the right

gating systems with the help of CATIA and MOLDFLOW

software (Gruber et al., 2011)A study on visual perceptual

measurement of sink markings on injection molding

components They study the sink marks of plastic parts

that are stable by increasing the holding pressure and other

parameters (X Wang et al., 2013)studied warpage and

sink defects with the help of rapid heat cycle molding

technology They study the effect of melting temperature,

injection time, packing pressure, packing time and cooling

time on the warpage with the help of Teguchi

andANOVA.(Gruber et al., 2014)Study visual acuity on

the sink markings of injection molded parts and develop

CCD images (Rathi, Salunke, 2012)consider the

parameters of injection pressure, mold closure speed, mold

pressure, rear pressure and short shot defect in the study of

the injection molding process (Raos & Stojsic,

2014)studied the effect of injection speed and injection

pressure of two processing parameters on the tensile

strength of the plastic molded component He did his

analysis on the polyethylene content in plastics They

showed that injection pressure was an important factor

influencing tensile content and that injection speed did not

affect tensile strength (Islam et al., 2013)studied the effect

of pressure factors on the tensile strength of metal injection

molding material They found that as the pressure

increases, the tensile strength of the molded part of the

metal increases (Li et al., 2007) studied the effects of

processing parameters on the presence of weldline by the

Taguchi experimental design method Welders are

obtained from the right door of the copy machine built

with three gates Images of mold products are taken with

digital cameras They are considered to be the major

factors influencing the strength of the material

polypropylene, such as the melting temperature, injection

pressure, and injection speed They showed that injection

speed is a major factor in the visibility of weld lines (P

Zhao et al., 2020)This review introduces methods and

strategies on the sensing, optimization, and control of

intelligent injection molding and summarizes recent

studies in these three areas (Q Wang et al., 2019)An experimental work is carried ou to study the effect of the micro injection molding parameters on the product weight

in this paper (Park & Dang, 2017)This work introduces a conformal cooling channels applied in a medium-size injection mold that makes an automotive part We improved an existent mold in order to reduce the cycle time and improve the quality of molded part (Chen et al., 2018)This article presents a method of efficiently designing a manufacturing process for injection molding

by determining the optimal Pareto Set of control factor settings; here these are the values of the melt temperature, packing time, packing pressure, and cooling time of the molding machine (Elduque et al., 2018)The importance of deeply analyzing the energy efficiency of the manufacturing process has been discussed in this study (Yu et al., 2020)The numerical calculation is carried out by combining the viscoelastic constitutive equation White-Metzner and the fiber orientation model iARD-RPR and then verified by experiment (Siregar et al., 2017)This paper present the design and development of an injection moulding machine for manufacturing lab that have features

of low cost, bench top size, and have similar proses as in commercial injection moulding machine (Wibowo et al., 2019)The results of the study of pure ABS recycling with recycle stated that the parameters of the melting temperature, injection pressure and holding pressure affect the optimal value of a result (Lou & Xiong, 2020)The MU viscosity model was established based on the ultrasonic energy, the characteristic micro dimension, and the molecular chain length Ultrasonic microinjection molding experiments were performed using microgrooves with different flow length ratios

Most researchers have studied the injection molding process with different process parameters, different materials and different mathematical techniques Some of them are listed below:

Table 1 Parameters and responses

1 General frameworks for

optimization of plastic

injection molding process

parameters

2014 Melt temperature, mold temperature, injection pressure, injection time, packing pressure, packing time etc

Poylcarbonate Warpage,

clamping force tensile strength, residiual stress ,cooling time

2 Optimization of Injection

Moulding Process using

Taguchi and ANOVA

2013 Melt Temperature, Injection pressure, cooling time

3 Analysis Of Injection

Moulding Process Parameters

2012 Injection pressure, mould closing speed,mouldpressure,b ack pressure

PC AND ABS blend polymer (PC/ABS) made by Chi- Mei Company

(Taiwan)

Warpage

4 Warpage control of

thin-walled injection molding

using local mold temperatures

2015 Mold temperature behavior offilling With Mold flow software

Reprocessed ABS polymer is used

Warpage

5 Effect of reprocessing on

shrinkage and mechanical

properties of ABS and

investigating the proper blend

of vergin and recycled ABS

in injection molding

2014 Young’s modulus Carbon steel

AISI 1050 used as a Mold material and ABS used as plastic material used

Warpage

6 The use of Taguchi method

in the design of plastic

injection mould for reducing

warpage

2007 Melt temperature (240-2900C),Filling Time (.1-.5sec.), Packingpressure,(C 60-90), Packing Time(.6-1)

PP material with 40% calcium carbonate

Warpage

7 The impact of process

parameter on test specimens

deviations and their

correlation with AE signals

captured during the injection

moulding cycle

2013 Coolling time(6- 10 sec),Packing time(3- 5sec),Packing pressure(300-500 bar),injection pressure (1000-1200 bar), injection speed (40-50 mm/sec), Melt temperature (230-2400C)

Polyacetal POM C9021 Shrinkage and

warpage

8 Comparison of the warpage

optimization in the plastic

injection molding using

2006 Mold temperature (60-900C),Melt

temperature(120-

PMMA-80

is used

Warpage

ANOVA, neural network

model and Geneticalgorithm

2800C),Packing Pressure(60-75 Mpa),Packing Time(10-20sec) Cooling time (9-15 sec)Runner type(Cicular, Hexagon,Trpeze, Gate location

9 A study of the effects of

process parameters for

injection molding on surface

quality of optical lenses

2009 Melt temperature (220-2300C), screwspeed (5-15 m/min ), injection speed(50- 90mm/sec), injection pressure (1100-1300 bar), Packing time

(7-13 sec),Mold temperature(60- 800C), Cooling rate(s)

Phenolic molding compound

is shown

Surface waviness, roughness, light transmission

10 Optimization of plastic

injection molding process

parameters for manufacturing

a brake booster valve body

2014 No of gates, Gate size (18.68 mm to

22.86 mm),mold temperature (147.6 - 180.4), resin temperature(85.5- 104.5),switch over by volumefilled (69.57- 85.03%),switch over injection pressure (10.8-13.2Mpa), Curing time(108-

132 s)

Polybutylen e terephthalate (PBT)

Resin viscosity, curing percentage

11 Improvement ofinjection

moulding processes by using

dual energysignatures

2014 Processingtime, power level

Poly propylene Energy consumption

12 Application of Taguchi

method in the optimization of

injection moulding

parameters for manufacturing

products from plasticblend

2010 Injection speed(10.74-10.98),Melting temperature (9.79-12.50),

Injection pressure (10.70-11.12), holding pressure(10.48- 11.47),holding time(10.36-11.15), cooling time(10.54- 11.60)

Polypropylene Shrinkage in cm

13 A principal component

analysis model-based

predictive controller for

controlling part warpage in

plastic injection molding

2015 Cavity pressure,cavity temperature

Warpage by coolant flow rate and cavity pressure temperature

14 Optimal cooling design 2013 Cooling time, injection –

time

GECycoloy C2950 PC/abs

Warpage, shrinkage, thermal residual stress,sink marks etc

15 Finding efficient frontier of

process parameters for

injectionmolding

2013 Injection time (.5- 1.5),injection pressure(100 to 140MPa),packing pressure(80-120 Mpa),Packing time (7.5-12.5)cooling time(14-

24sec),coolant temperature(20-30), mold open time(4-6 sec),melt

temperature(270- 280),moldsurface temperature(65-75)

Polyamide PAT considered

Shrinkage and warpage

16 Simulation and experimental

study indeterming

Injection molding process

parameters for thin-shell

plasticparts via design of

experimentanalysis

2009 Melt temperature(310- 330),Mold

temperature (115- 135),injection Speed (%65-85), Packing pressure (40-45 Mpa)

Polypropylene and polystyrene

Shrinkage and warpage

17 Parameter study in injection

molding process using

statistical methods and

Invasive WEED algorithm

2011 Melting temperature(240- 260),Injection Pressure(50- 70),Packing Pressure (50-

70MPA),Packing time(5-15 sec)

Ultramid B3S (un- reinforced PA6 material)

Shrinkage and Warpage

18 Optimisation of

injection moulded parts by using ANN-

PSO approach

2006 Mold temperature(40- 80),Melt temperature (250-270),Flow rate

(10-80,103*mm3/sec),pack ing

pressure(25-40 Mpa)

19 Back propagation neural

network modeling for

warpage prediction and

optimization of plastic

products during injection

molding

2011 Mold temperature(40- 80), Melt

temperature(200- 280), packing pressure(80- 120),Packing time(8- 12),Cooling time(15- 25)

Polypropylene Warpage

20 Reducing the shrinkage in

Plastic injection moulded gear

by GREY based Taguchi

optimization method

2012 Melt temperature(200- 240),Packing

pressure(60- 80),Packing time(5- 15),Cooling time(30- 50)

Powder material is used Shrinkage

21 The use of Taguchi approach

to determine the influence of

injection-moulding

parameters on the properties

of green parts

2006 Injection speed, mould temperature, material temperature, holding pressure,

holding pressure time,cCycle

time(15-30 sec)

Polypropylene Shrinkage

22 A hybrid of back propagation

neural network and genetic

algorithm for optimization of

injection molding process

parameter

2011 Mold temperature, melt temperature, packing pressure, packingtime, cooling time

clamp force analysis

23 Practical application of

Taguchi method for

optimization processing

parameters for plastic

injection moulding- A

retrospective review

2013 Mould temperature, melt temperature, Gate dimension, packing pressure,packingtime,i njectiontime,fiiling time filling pressure, cooling time

Warpage

24 Development of a smart

plastic injection mold with

conformal cooling channels

2017 Mold Temperature , cooling time, Flow nature, Cycle time, Selective laser melting

Cooling time

25 Effect of Process Parameters

on Repeatability Precision of

Weight for Microinjection

Molding Products

2019 Packing pressure, cavity pressure, mold temperature, injection pressure

Polypropylene(5 090T) (MFI=15g/10min) Formosa petrochemical Corp,Taiwan

Tensile strength

26 Intelligent Injection Molding

on Sensing, Optimization, and

Control

2020 Process sensing, process control, Taguchi method, intelligent method(

case based reasoning)

Warpage, shrinkage, mechanical properties, clamping force

27 Sequential design of an

injection molding process

using a calibrated predictor

2018 Bayestan analysis, melt temperature, packing

time, packing pressure, cooling time

Shrinkage

28 Numerical Simulation during

Short-Shot Water-Assisted

Injection Molding Based on

the Overflow Cavity for

Short-Glass Fiber-Reinforced

Polypropylene

2020 Melt short shot size, water injection delay time, melt temperature, water injection

pressure

Glass fiber reinforced polyethylene (SGFPP, Grade Hostacom

SB224-1, Lyondell Basell Industries, Germany)

Residual wall thickness

29 Design and development of

injection moulding machine

for manufacturing maboratory

2017 Flow rate, packing time

Design process

30 Research of Injection

Molding Parameters with

Acrylonitrile Butadiene

Styrene Composition

Recycled Against Mechanical

Properties

2019 melting temperature, injection pressure, holding pressure

Recycled ABS combined with pure material on 10%:90%,

20%:80% and 30%:70%

Impact strength and tensile strength

Since raw materials are scarce and expensive, and energy

costs are also increasing, mold design strategy should

reduce costs and reduce resource consumption

Contraction, Warpage, sink marks, and weld lines are the

four most challenging defects in the injection mold In

many cases, their formation is inevitable, especially for

complex geometric components

There is a lot of effort in this area But some of them have been successful, so this area needs special attention This is because we know that many errors are caused by processing parameters based on this study So the production control of processing parameters is necessary for the product Based on the above table we find that each researcher focuses mostly on warpage and

contraction They also pay attention to the sink marks

But some researchers pay attention to weld lines and

tensile strength We have found from above that the study

of recycling of plastics is necessary for the benefit of the

community It requires environmental friendly,

recyclable material identification

Therefore processing in this area should be done So in

order to increase the production of quality-based plastic

products, studies on other process parameters are needed,

which should be free of flaws

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